Aerotech Automation1 iXC4 Hardware Manual
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Aerotech Automation1 iXC4 Hardware Manual

Pwm digital drives
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Automation1 iXC4 and XC4
PWM Digital Drives
HARDWARE MANUAL
Revision 2.04

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Summary of Contents for Aerotech Automation1 iXC4

  • Page 1: Automation1 Ixc4 And Xc4 Pwm Digital Drives

    Automation1 iXC4 and XC4 PWM Digital Drives HARDWARE MANUAL Revision 2.04...
  • Page 2 Global Technical Support Portal for information and support about your Aerotech, Inc. products. The website supplies software, product manuals, Help files, training schedules, and PC-to-PC remote technical support. If necessary, you can complete Product Return (RMA) forms and get information about repairs and spare or replacement parts.

  • Page 3: Table Of Contents

    Hardware Manual Table of Contents Table of Contents Automation1 iXC4 and XC4 PWM Digital Drives Table of Contents List of Figures List of Tables EU Declaration of Conformity Agency Approvals Safety Procedures and Warnings Handling and Storage Installation Overview Chapter 1: iXC4/XC4 Overview 1.1.
  • Page 4 3.3. Analog Outputs [-EB1] 3.4. Analog Inputs [-EB1] 3.5. PSO Interface [-EB1] Chapter 4: Cables and Accessories 4.1. Joystick Interface 4.2. Handwheel Interface Chapter 5: Maintenance 5.1. Preventative Maintenance 5.2. Fuse Specifications Appendix A: Warranty and Field Service Appendix B: Revision History Index www.aerotech.com...

  • Page 5: List Of Figures

    Digital Outputs Connected in Current Sourcing Mode Figure 2-40: Digital Outputs Connected in Current Sinking Mode Figure 2-41: Digital Inputs Schematic (Aux I/O Connector) Figure 2-42: Digital Inputs Connected to Current Sourcing Devices Figure 2-43: Digital Inputs Connected to Current Sinking Devices www.aerotech.com...
  • Page 6 Two Axis Joystick Interface (to the Aux I/O of two drives) Figure 4-2: Two Axis Joystick Interface (to the I/O board) Figure 4-3: Handwheel Interconnection to Aux I/O Connector Figure 4-4: Handwheel Interconnection to the Aux I/O through a BBA32 Module www.aerotech.com...

  • Page 7: List Of Tables

    Motor Power Output Connector Pinout Table 2-8: Mating Connector Part Numbers for the Motor Power Output Connector Table 2-9: Wire Colors for Aerotech-Supplied Brushless Motor Cables  Table 2-10: Hall Signal Diagnostics Table 2-11: Wire Colors for Aerotech-Supplied DC Brush Motor Cables...
  • Page 8 Table 3-18: PSO Interface Connector Pinout [-EB1] Table 3-19: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] Table 4-1: Standard Interconnection Cables Table 5-1: LED Description Table 5-2: Troubleshooting Table 5-3: Preventative Maintenance Table 5-4: Control Board Fuse Specifications www.aerotech.com...

  • Page 9: Eu Declaration Of Conformity

    Hardware Manual EU Declaration of Conformity EU Declaration of Conformity Manufacturer Aerotech, Inc. Address 101 Zeta Drive Pittsburgh, PA 15238-2811 Product iXC4/XC4 Model/Types This is to certify that the aforementioned product is in accordance with the applicable requirements of the following directive(s):...

  • Page 10: Agency Approvals

    IEC 62061:2005 (up to SILCL3), IEC 62061:2005/AMD1:2012 (up to SILCL3), IEC 62061:2005/AMD2:2015 (up to SILCL3) Visit https://www.tuev-sued.de/product-testing/certificates to view Aerotech's TÜV SÜD certificates. Type the certificate number listed above in the search bar or type "Aerotech" for a list of all Aerotech certificates. www.aerotech.com...

  • Page 11: Safety Procedures And Warnings

    To find the newest information about this product, refer to www.aerotech.com. If you do not understand the information in this manual, contact Aerotech Global Technical Support. IMPORTANT: This product has been designed for light industrial manufacturing or laboratory environments.
  • Page 12 2. Do not use the cables or the connectors to lift or move this product. 3. Use this product only in environments and operating conditions that are approved in this manual. 4. Only trained operators should operate this equipment. www.aerotech.com...

  • Page 13: Handling And Storage

    Store the drive in the original shipping container. If the original packaging included ESD protective packaging, make sure to store the drive in it. The storage location must be dry, free of dust, free of vibrations, and flat. Section 1.3. Environmental Specifications Refer to www.aerotech.com...

  • Page 14: Installation Overview

    2.5./ (if you purchased the I/O option). Chapter 3 Connect the Safe Torque Off (STO). Section 2.4. Connect the power supply to the Control Supply connector. Section 2.1.1. Connect the motor power to the Motor Supply connector. Section 2.1.2. www.aerotech.com...
  • Page 15 2.5./ (if you purchased the I/O option). Chapter 3 Connect the Safe Torque Off (STO). Section 2.4. Connect the power supply to the Control Supply connector. Section 2.1.1. Connect the motor power to the Motor Supply connector. Section 2.1.2. www.aerotech.com...
  • Page 16 Installation Overview iXC4/XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 17: Chapter 1: Ixc4/Xc4 Overview

    And both drives are offered with an optional encoder interpolation feature (-MX1), an auxiliary encoder input for dual loop control, dedicated analog and digital I/O (expandable with the -EB1 option), and separate power connections for motor and control supply voltages. Figure 1-1: iXC4 Digital Drive-Based Controller Labeled www.aerotech.com...

  • Page 18: Figure 1-2: Xc4 Digital Drive Labeled

    Chapter 1: iXC4/XC4 Overview iXC4/XC4 Hardware Manual Figure 1-2: XC4 Digital Drive Labeled www.aerotech.com...

  • Page 19: Table 1-1: Features And Options

    -PSO1 One-axis PSO firing (includes One-axis Part-Speed PSO) External Shunt (Section 2.8.) -SX0 No connector for the External Shunt -SX1 Connection provided for an external shunt resistor network Version -DEFAULT Firmware Matches Software Line -LEGACY Legacy Firmware Version X.XX.XXX www.aerotech.com...

  • Page 20: Figure 1-3: Functional Diagram

    Chapter 1: iXC4/XC4 Overview iXC4/XC4 Hardware Manual The block diagram that follows shows a summary of the connector signals. Figure 1-3: Functional Diagram www.aerotech.com...

  • Page 21: Electrical Specifications

    Optical and transformer isolation between control and Isolation power stages. (1) AC input voltage and load dependent.  (2) Dependent on total output power: efficiency increases with increasing output power. (3) Current is measured as the peak amplitude in any motor phase www.aerotech.com...

  • Page 22: System Power Requirements

    Power Loss = 3 * I(rms)^2 * R(line-line)/2 Power Input = (Power Output + Power Loss) / EfficiencyFactor DC Brush Motor Power Output [W] = Torque [N·m] * Angular velocity[rad/sec] Power Loss = I(rms)^2 * R Power Input = (Pout + Ploss) / EfficiencyFactor www.aerotech.com...

  • Page 23: Mechanical Specifications

    IP54 Compliant Weight ~2.36 kg Mounting Hardware M4 [#8] screws (four locations, not included) Mounting Orientation Vertical (typical) Section 1.2.2. Dimensions Dimensions Refer to Airflow ~25 mm Minimum Clearance Connectors ~100 mm Operating Temperature Section 1.3. Environmental Specifications Refer to www.aerotech.com...

  • Page 24: Dimensions

    1.2.2. Dimensions iXC4/XC4 Hardware Manual 1.2.2. Dimensions IMPORTANT: iXC4 and XC4 dimensions are the same. iXC4 is shown. Figure 1-4: Dimensions www.aerotech.com...

  • Page 25: Figure 1-5: Dimensions [-Eb1]

    Hardware Manual 1.2.2. Dimensions IMPORTANT: iXC4-EB1 and XC4-EB1 dimensions are the same. iXC4-EB1 is shown. Figure 1-5: Dimensions [-EB1] www.aerotech.com...

  • Page 26: Environmental Specifications

    0 m to 2,000 m (0 ft to 6,562 ft) above sea level. Operating Altitude If you must operate this product above 2,000 m or below sea level, contact Aerotech, Inc. Pollution Degree 2 Pollution Typically only nonconductive pollution occurs.

  • Page 27: Drive And Software Compatibility

    Last Software Version column, drives that show a specific version number are not supported after that version. Table 1-5: Drive and Software Compatibility Drive Type Software First Software Version Last Software Version iXC4 Automation1 2.0.0 Current Automation1 1.2.0 Current A3200 6.04 Current www.aerotech.com...
  • Page 28 1.4. Drive and Software Compatibility iXC4/XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 29: Chapter 2: Installation And Configuration

    The Control Supply contains an internal filter but you could be required to add an external filter for CE compliance. Install the external filter as close as possible to the drive. Use a Schaffner FN2080 filter, an Aerotech UFM-ST noise filter module, or equivalent device. IMPORTANT: Refer to local electrical safety requirements to correctly size external system wires.

  • Page 30: Motor Supply Connector

    IMPORTANT: Before you operate the iXC4/XC4, install a ground connection for your safety and to prevent damage to the equipment. For CE compliance, Aerotech recommends that you use an AC line filter. Connect the filter as close as possible to the drive. For more information about the AC line filter, refer to Section 2.1.4.

  • Page 31: Transformer Options

    Generate 56 VAC from 115 VAC or 230 VAC input source voltage. When TV0.3-56 rectified by the drive, it produces an 80 VDC power bus. 1.5 kVA, 2.5 kVA, or 5 kVA isolation transformer; 115/230 VAC input; 28, 43, TV1.5, TV2.5, or TV5 56, 70, 115 VAC output www.aerotech.com...

  • Page 32: Figure 2-3: Tv0.3-28-56-St Transformer Control And Motor Power Wiring (40 Vdc Bus)

    2.1.3. Transformer Options iXC4/XC4 Hardware Manual Figure 2-3: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (40 VDC Bus) www.aerotech.com...

  • Page 33: Figure 2-4: Tv0.3-28-56-St Transformer Control And Motor Power Wiring (80 Vdc Bus)

    Hardware Manual 2.1.3. Transformer Options Figure 2-4: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (80 VDC Bus) www.aerotech.com...

  • Page 34: Figure 2-5: Tv0.3-28-56-St Transformer Control And Motor Power Wiring (160 Vdc Bus)

    2.1.3. Transformer Options iXC4/XC4 Hardware Manual Figure 2-5: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (160 VDC Bus) www.aerotech.com...

  • Page 35: Figure 2-6: Tv0.3-28 Transformer Control And Motor Power Wiring (40 Vdc Bus)

    Hardware Manual 2.1.3. Transformer Options Figure 2-6: TV0.3-28 Transformer Control and Motor Power Wiring (40 VDC Bus) www.aerotech.com...

  • Page 36: Figure 2-7: Tv0.3-56 Transformer Control And Motor Power Wiring (80 Vdc Bus)

    2.1.3. Transformer Options iXC4/XC4 Hardware Manual Figure 2-7: TV0.3-56 Transformer Control and Motor Power Wiring (80 VDC Bus) www.aerotech.com...

  • Page 37: Figure 2-8: Tm3/Tm5 Transformer Control And Motor Power Wiring

    Hardware Manual 2.1.3. Transformer Options Figure 2-8: TM3/TM5 Transformer Control and Motor Power Wiring www.aerotech.com...

  • Page 38: Minimizing Noise For Emc/Ce Compliance

    Use a line filter, such as Aerotech’s UFM-ST, on the Motor Supply and Control Supply AC inputs. 4. Use the lowest motor voltage required by the application to reduce radiated emission.

  • Page 39: Motor Power Output Connector

    Stepper Brushless Phase C Motor Lead 1.3 mm (#16 AWG) DC Brush - Stepper Return Table 2-8: Mating Connector Part Numbers for the Motor Power Output Connector Aerotech Third Part Screw Wire Size: Type Torque: Nm [AWG] 7-Pin Terminal Block ECK02387 Phoenix 1756353 0.5 - 0.6...

  • Page 40: Brushless Motor Connections

    Black #3 Violet & Blue (1) Wire Color Set #1 is the wire set typically used by Aerotech. (2) “&” indicates two wires (Red & Orange); “ / ” indicates a single wire (Green/White). Brushless motors are commutated electronically by the controller. The use of Hall effect devices for commutation is recommended.

  • Page 41: Brushless Motor Powered Motor And Feedback Phasing

    Observe the state of the encoder and Hall-effect device signals in the Diagnostics section of the Status Utility. Table 2-10: Hall Signal Diagnostics Hall-Signal Status Definition 0 V or logic low 5 V or logic high Figure 2-10: Positive Motor Direction Figure 2-11: Encoder and Hall Signal Diagnostics www.aerotech.com...

  • Page 42: Brushless Motor Unpowered Motor And Feedback Phasing

    With the designations of the motor and Hall leads of a third party motor determined, the motor can now be connected to an Aerotech system. Connect motor lead A to motor connector A, motor lead B to motor connector B, and motor lead C to motor connector C. Hall leads should also be connected to their respective feedback connector pins (Hall A lead to the Hall A feedback pin, Hall B to Hall B, and Hall C to Hall C).

  • Page 43: Dc Brush Motor Connections

    Yellow & Blue Black Yellow & Blue (1) Wire Color Set #1 is the typical wire set used by Aerotech. (2) “&” (Red & Orange) indicates two wires; “ / ” (Green/White) indicates a single wire. 2.2.2.1. DC Brush Motor Phasing A properly phased motor means that the positive motor lead should be connected to the ØA motor...

  • Page 44: Stepper Motor Connections

    Yellow White White & Red (1) Wire Color Set #1 is the typical wire set used by Aerotech. (2) “&” (Red & Orange) indicates two wires; “ / ” (Green/White) indicates a single wire. 2.2.3.1. Stepper Motor Phasing A stepper motor can be run with or without an encoder.

  • Page 45: Three Phase Stepper Motor Connections

    2-19). If the motor moves in a counterclockwise direction, reverse the motor leads and re-run the command. After the motor has been phased, if you want to change the direction of positive motion, use the ReverseMotionDirection parameter. Figure 2-19: Positive Motor Direction www.aerotech.com...

  • Page 46: Feedback Connector

    Pin # Description In/Out/Bi Connector Reserved Motor Over Temperature Thermistor Input +5V Power Output Plug and Play Serial Data (for Aerotech stages only) Bidirectional Hall-Effect Sensor B (brushless motors only) Input Encoder Marker Reference Pulse - Input Absolute Encoder Clock - Output...

  • Page 47: Primary Encoder Inputs

    Bidirectional Encoder Cosine + Input Encoder Cosine - Input +5V Power Output Encoder Sine + Input Encoder Sine - Input Absolute Encoder Data+ Bidirectional Signal Common Output Signal Common Output (1) The maximum combined current output is 500 mA. www.aerotech.com...

  • Page 48: Square Wave Encoder (Primary)

    Table 2-17: Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum (25 ns minimum edge separation) x4 Quadrature Decoding 40 million counts/sec Figure 2-20: Square Wave Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 49: Absolute Encoder (Primary)

    You cannot echo an absolute encoder signal. Refer to Figure 2-21 for the serial data stream interface. Refer to the Help file for information on how to set up your EnDat or BiSS absolute encoder parameters. Figure 2-21: Absolute Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 50: Sine Wave Encoder (Primary) [-Mx1 Option]

    450 kHz, 2 MHz Input Amplitude 0.6 to 1.75 Vpk-pk Interpolation Factor (max) 16,384 Input Common Mode 1.5 to 3.5 VDC (1) Measured as SIN(+) - SIN(-) or COS(+) - COS(-) Figure 2-22: Sine Wave Encoder Phasing Reference Diagram www.aerotech.com...

  • Page 51: Figure 2-23: Sine Wave Encoder Schematic (Feedback Connector)

    Hardware Manual 2.3.1.3. Sine Wave Encoder (Primary) [-MX1 Option] Figure 2-23: Sine Wave Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 52: Encoder Phasing

    Figure 2-24: Encoder Phasing Reference Diagram (Standard) IMPORTANT: Encoder manufacturers may refer to the encoder signals as A, B, and Z. The proper phase relationship between signals is shown in Figure 2-24. Figure 2-25: Position Feedback in the Diagnostic Display www.aerotech.com...

  • Page 53: Hall-Effect Inputs

    Hall-Effect Sensor A (brushless motors only) Input Hall-Effect Sensor C (brushless motors only) Input +5V Power Output Signal Common Output Signal Common Output (1) The maximum combined current output is 500 mA. Figure 2-26: Hall-Effect Inputs Schematic (Feedback Connector) www.aerotech.com...

  • Page 54: Thermistor Input

    1.385 kΩ. The circuit includes a 12 kΩ internal pull-up resistor which corresponds to a trip voltage of +0.52 V. Table 2-20: Thermistor Input Pin on the Feedback Connector Pin # Description In/Out/Bi Motor Over Temperature Thermistor Input Figure 2-27: Thermistor Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 55: Encoder Fault Input

    The nominal trip voltage of the encoder fault input is +2.5 V. Table 2-21: Encoder Fault Input Pin on the Feedback Connector Pin # Description In/Out/Bi Encoder Fault Input Input Figure 2-28: Encoder Fault Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 56: End Of Travel And Home Limit Inputs

    IMPORTANT: Use NPN-type normally-closed limit switches (Active High) to provide fail- safe behavior in the event of an open circuit. www.aerotech.com...

  • Page 57: Figure 2-29: End Of Travel And Home Limit Input Connections

    Hardware Manual 2.3.5. End of Travel and Home Limit Inputs Figure 2-29: End of Travel and Home Limit Input Connections Figure 2-30: End of Travel and Home Limit Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 58: End Of Travel And Home Limit Phasing

    CW and CCW limit functionality in the software using the EndOfTravelLimitSetup parameter. View the logic level of the EOT limit inputs in the Diagnostics display (shown in Figure 2-31). Figure 2-31: End of Travel and Home Limit Input Diagnostic Display www.aerotech.com...

  • Page 59: Brake Outputs

    Brake Output +  Output Table 2-24: Brake Control Specifications Specification Value Maximum Voltage 24 VDC Maximum Current A varistor must be connected across the brake to minimize voltage transients. Figure 2-32: Brake Connected to the 25-Pin Feedback Connector (Typical) www.aerotech.com...

  • Page 60: Safe Torque Off Input (Sto)

    Input Use only to defeat STO by connecting to Power Supply - Output RETURN. Not for customer use. Table 2-26: Mating Connector Part Numbers for the STO Connector Tightening Aerotech Phoenix Torque Wire Size: Description (Nm) AWG [mm 5-Pin Terminal Block...

  • Page 61: Figure 2-33: Typical Sto Configuration

    WARNING: The drive does not check for short circuits on the external STO wiring. If this is not done by the external safety device, short circuits on the wiring must be excluded. Refer to EN ISO 13849-2. For Category 4 systems, the exclusion of short circuits is mandatory. Figure 2-33: Typical STO Configuration www.aerotech.com...

  • Page 62: Sto Standards

    Interval for manual STO test: EN/IEC 61508 Once per year for SIL2/PL d/category 3 Once per three months for SIL3/PL e/category 3 Once per day for SIL3/PL e/category 4 SIL3 EN/IEC 61508 PFH < 3 FIT SFF > 99% www.aerotech.com...

  • Page 63: Sto Functional Description

    Connect the ESTOP signal directly to a digital input, in addition to the external timer, to allow the drive to begin a software-controlled stop as soon as the ESTOP signal becomes active. Use the EmergencyStopFaultInput [A3200: ESTOPFaultInput] parameter to configure a digital input as an ESTOP input. www.aerotech.com...

  • Page 64: Sto Startup Validation Testing

    (open circuit or 0 V), and that the STO channel is in the safe state. DANGER: The STO circuit does not remove lethal voltage from the motor terminals. AC mains power must be removed before servicing. www.aerotech.com...

  • Page 65: Sto Diagnostics

    If power is reapplied to the STO inputs before the STO Delay Time, an STO hardware shutdown will not occur but a software stop may, depending on the width of the STO pulse. The controller will ignore STO active pulses shorter in length than the STOPulseFilter parameter setting. www.aerotech.com...

  • Page 66: Auxiliary I/O Connector

    (2) For PSO, refer to Section 2.5.2. Table 2-34: Mating Connector Part Numbers for the Auxiliary I/O Connector Mating Connector Aerotech P/N Third Party P/N Connector ECK01259 Kycon K86-AA-26P Backshell ECK01022 Amphenol 17-1725-2 NOTE: These items are provided as a set under the Aerotech P/N: MCK-26HDD. www.aerotech.com...

  • Page 67: Auxiliary Encoder Inputs

    Absolute Encoder Clock + Output Auxiliary Cosine- Bidirectional Absolute Encoder Clock - Output +5 Volt (500 mA max) Output Auxiliary Marker- / PSO output / TTL Output Bidirectional Auxiliary Marker+ / PSO output Bidirectional Common Output (2) For PSO, refer to Section 2.5.2. www.aerotech.com...

  • Page 68: Square Wave Encoder (Auxiliary)

    Table 2-36: Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum (25 ns minimum edge separation) x4 Quadrature Decoding 40 million counts/sec Figure 2-35: Square Wave Encoder Interface (Aux I/O Connector) www.aerotech.com...

  • Page 69: Absolute Encoder (Auxiliary)

    You cannot use an absolute encoder with incremental signals on the Auxiliary I/O Connector. Refer to Figure 2-36 for the serial data stream interface. Refer to the Help file for information on how to set up your EnDat or BiSS absolute encoder parameters. Figure 2-36: Absolute Encoder Schematic (Auxiliary I/O Connector) www.aerotech.com...

  • Page 70: Position Synchronized Output (Pso)

    12.5 MHz Output Latency 15 ns RS-422 15 ns [Fire event to output change] Table 2-38: PSO Pins on the Auxiliary I/O Connector Pin# Description In/Out/Bi Auxiliary Marker- / PSO output / TTL Output Bidirectional Auxiliary Marker+ / PSO output Bidirectional Common Output www.aerotech.com...

  • Page 71: Figure 2-37: Pso Interface

    Hardware Manual 2.5.2. Position Synchronized Output (PSO) Figure 2-37: PSO Interface www.aerotech.com...

  • Page 72: Digital Outputs

    Reset State Output Off (High Impedance State) Table 2-40: Digital Output Pins on the Auxiliary I/O Connector Pin# Description In/Out/Bi Digital Output 0 Output Digital Output 1 Output Digital Output 2 Output Digital Output Common Output Digital Output 3 Output www.aerotech.com...

  • Page 73: Figure 2-38: Digital Output Schematic (Aux I/O Connector)

    Hardware Manual 2.5.3. Digital Outputs Figure 2-38: Digital Output Schematic (Aux I/O Connector) www.aerotech.com...

  • Page 74: Figure 2-39: Digital Outputs Connected In Current Sourcing Mode

    2.5.3. Digital Outputs iXC4/XC4 Hardware Manual Figure 2-39: Digital Outputs Connected in Current Sourcing Mode Figure 2-40: Digital Outputs Connected in Current Sinking Mode www.aerotech.com...

  • Page 75: Digital Inputs

    Digital Input 0 / CCW EOT Input Input Digital Input 1 / CW EOT Input Input Digital Input Common Output Digital Input 2 / Home Input Input Digital Input 3 Input (1) Software configured option Figure 2-41: Digital Inputs Schematic (Aux I/O Connector) www.aerotech.com...

  • Page 76: Figure 2-42: Digital Inputs Connected To Current Sourcing Devices

    2.5.4. Digital Inputs iXC4/XC4 Hardware Manual Figure 2-42: Digital Inputs Connected to Current Sourcing Devices Figure 2-43: Digital Inputs Connected to Current Sinking Devices www.aerotech.com...

  • Page 77: High-Speed Inputs

    High-Speed Input Pins on the Auxiliary I/O Connector Pin# Description In/Out/Bi High-Speed Input 20 + / PSO External Sync. + Input High-Speed Input 20 - / PSO External Sync. - Input High-Speed Input 21 + Input High-Speed Input 21 - Input Figure 2-44: High-Speed Inputs www.aerotech.com...

  • Page 78: Analog Output

    Output Voltage -10 V to +10 V Output Current 5 mA Resolution (bits) 16 bits Table 2-46: Analog Output Pins on the Auxiliary I/O Connector Pin# Description In/Out/Bi Analog Output 0 Output Analog Common Output Figure 2-45: Analog Output 0 Schematic www.aerotech.com...

  • Page 79: Analog Input 0 (Differential)

    1. Signals outside of this range may damage the input Table 2-48: Analog Input Pins on the Auxiliary I/O Connector Pin# Description In/Out/Bi Analog Input 0+ (Differential) Input Analog Input 0- (Differential) Input Analog Common Output Figure 2-46: Analog Input 0 Schematic www.aerotech.com...

  • Page 80: Brake Power Supply Connector

    Pin# Description In/Out/Bi Brake Power Supply (+) Input Brake Power Supply (-) Input Table 2-50: Mating Connector Part Numbers for the Brake Power Supply Connector Aerotech Wire Size: Tightening Description Phoenix P/N AWG [mm Torque (Nm) 2-Pin Terminal Block ECK02390 1827616 0.22 - 0.25...

  • Page 81: Hyperwire Interface

    HyperWire Cable Part Numbers Part Number Description HYPERWIRE-AO10-5 HyperWire cable, active optical, 0.5 m HYPERWIRE-AO10-10 HyperWire cable, active optical, 1.0 m HYPERWIRE-AO10-30 HyperWire cable, active optical, 3.0 m HYPERWIRE-AO10-50 HyperWire cable, active optical, 5.0 m HYPERWIRE-AO10-200 HyperWire cable, active optical, 20.0 m www.aerotech.com...

  • Page 82: External Shunt Option [-Sx1]

    Table 2-53: -SX1 Component Information Component Description Aerotech P/N 50 Ω (min), 300 W Recommended Shunt Resistor ECR01039 Vishay/Dale: RBEF030050R00KFBVT Screw Torque Value: 0.6 - 0.8 N·m Wire Size: 0.2 - 6 mm...

  • Page 83: Table 2-54: Maximum Additional Storage Energy For A Standard Ixc4/Xc4

    Equation 4:     average power dissipated on shunt resistor (W) time between deceleration events (s) CYCLE Equation 5:    hysteresis voltage of regeneration circuit (V) [10 V, Typical] Additional useful equations: 1 lb·ft = 1.356 N·m 1 rad/s = 9.55 rpm www.aerotech.com...

  • Page 84: Sync Port

    Length 3 dm; Connectors: USB Type A to USB Type A CBL-SYNC-5 Length 5 dm; Connectors: USB Type A to USB Type A CBL-SYNC-7 Length 7 dm; Connectors: USB Type A to USB Type A CBL-SYNC-10 Length 10 dm; Connectors: USB Type A to USB Type A www.aerotech.com...

  • Page 85: System Interconnection

    Hardware Manual 2.10. System Interconnection 2.10. System Interconnection Figure 2-47: Drive-Based System Wiring Drawing (Best Practice) Figure 2-48: PC-Based System Wiring Drawing (Best Practice) www.aerotech.com...

  • Page 86: Figure 2-49: Drive-Based Controller System Interconnection (Best Practice)

    2.10. System Interconnection iXC4/XC4 Hardware Manual Figure 2-49: Drive-Based Controller System Interconnection (Best Practice) www.aerotech.com...

  • Page 87: Figure 2-50: Pc-Based Controller System Interconnection (Best Practice)

    Hardware Manual 2.10. System Interconnection Figure 2-50: PC-Based Controller System Interconnection (Best Practice) www.aerotech.com...

  • Page 88: Pc Configuration And Operation Information

    2.11. PC Configuration and Operation Information iXC4/XC4 Hardware Manual 2.11. PC Configuration and Operation Information For more information about hardware requirements, PC configuration, programming, system operation, and utilities, refer to the Help file. www.aerotech.com...

  • Page 89: Chapter 3: -Eb1 I/O Option Board

    Chapter 3: -EB1 I/O Option Board Chapter 3: -EB1 I/O Option Board The -EB1 I/O option board has 16 digital inputs, 16 digital outputs, 3 analog inputs, 3 analog outputs, and PSO outputs. Figure 3-1: -EB1 I/O Option Board Connectors (iXC4 shown) www.aerotech.com...

  • Page 90: Digital Outputs [-Eb1]

    24 V (26 V Maximum) Maximum Sink/Source Current 250 mA/output Output Saturation Voltage 0.9 V at maximum current Output Resistance 3.7 Ω Rise / Fall Time 250 µs (2K pull up to 24V) Reset State Output Off (High Impedance State) www.aerotech.com...

  • Page 91: Table 3-2: Digital Output 1 Connector Pinout [-Eb1]

    Output 11 (Optically-Isolated) Output Table 3-3: Mating Connector Part Numbers for the Digital Output 1 Connector [-EB1] Wire Size: mm [AWG] Mating Connector Aerotech P/N Third Party P/N 10-Pin Terminal Block ECK02395 Phoenix 1700841 0.5 - 0.14 [20-26] Table 3-4:...

  • Page 92: Figure 3-2: Digital Outputs Schematic [-Eb1]

    3.1. Digital Outputs [-EB1] iXC4/XC4 Hardware Manual Figure 3-2: Digital Outputs Schematic [-EB1] www.aerotech.com...

  • Page 93: Figure 3-3: Digital Outputs Connected In Current Sourcing Mode [-Eb1]

    Hardware Manual 3.1. Digital Outputs [-EB1] Figure 3-3: Digital Outputs Connected in Current Sourcing Mode [-EB1] Figure 3-4: Digital Outputs Connected in Current Sinking Mode [-EB1] www.aerotech.com...

  • Page 94: Digital Inputs [-Eb1]

    Input Input 11 (Optically-Isolated) Input Table 3-8: Mating Connector Part Numbers for the Digital Input 1 Connector [-EB1] Wire Size: mm [AWG] Mating Connector Aerotech P/N Third Party P/N 10-Pin Terminal Block ECK02395 Phoenix 1700841 0.5 - 0.14 [20-26] www.aerotech.com...

  • Page 95: Figure 3-5: Digital Inputs Schematic [-Eb1]

    Input 19 (Optically-Isolated) Input Table 3-10: Mating Connector Part Numbers for the Digital Input 2 Connector [-EB1] Wire Size: mm [AWG] Mating Connector Aerotech P/N Third Party P/N 10-Pin Terminal Block ECK02395 Phoenix 1700841 0.5 - 0.14 [20-26] Figure 3-5: Digital Inputs Schematic [-EB1] www.aerotech.com...

  • Page 96: Figure 3-6: Digital Inputs Connected To Current Sourcing (Pnp) Devices [-Eb1]

    IMPORTANT: Each bank of four inputs must be connected in an all sourcing or all sinking configuration. Figure 3-6: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] Figure 3-7: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] www.aerotech.com...

  • Page 97: Analog Outputs [-Eb1]

    Output Ground Table 3-13: Mating Connector Part Numbers for the Analog Output Connector [-EB1] Wire Size: mm [AWG] Type Aerotech P/N Third Party P/N 4-Pin Terminal Block ECK02399 Phoenix 1768004 0.5- 0.14 [20-26] Figure 3-8: Analog Output Typical Connection [-EB1]...

  • Page 98: Analog Inputs [-Eb1]

    Input Ground Table 3-16: Mating Connector Part Numbers for the Analog Input Connector [-EB1] Wire Size: mm [AWG] Mating Connector Aerotech P/N Third Party P/N 8-Pin Terminal Block ECK02397 Phoenix 1908101 0.5 - 0.14 [20-26] Figure 3-9: Analog Input Typical Connection [-EB1]...

  • Page 99: Pso Interface [-Eb1]

    Output PSO Output- Output PSO Output (TTL) Output Ground Table 3-19: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] Wire Size: mm [AWG] Type Aerotech P/N Third Party P/N 4-Pin Terminal Block ECK02399 Phoenix 1768004 0.5- 0.14 [20-26] www.aerotech.com...

  • Page 100: Figure 3-10: Pso Output Sources Current

    This output signal is a 5V TTL signal which is used to drive an opto coupler or general purpose TTL input. This signal is active high and is driven to 5V when a PSO fire event occurs. Figure 3-12: PSO TTL Outputs Schematic www.aerotech.com...

  • Page 101: Chapter 4: Cables And Accessories

    Hardware Manual Chapter 4: Cables and Accessories Chapter 4: Cables and Accessories IMPORTANT: Find Aerotech cable drawings on the website at http://www.aerotechmotioncontrol.com/manuals/index.aspx. Table 4-1: Standard Interconnection Cables Cable Part # Description Joystick Refer to Section 4.1. ECZ01231 BBA32 Interconnect Cable...

  • Page 102: Joystick Interface

    Hardware Manual 4.1. Joystick Interface Aerotech Multi-Axis Joystick (NEMA12 (IP54) rated) is powered from 5 V and has a nominal 2.5 V output in the center detent position. Three buttons are used to select axis pairs and speed ranges.

  • Page 103: Figure 4-2: Two Axis Joystick Interface (To The I/O Board)

    Hardware Manual 4.1. Joystick Interface Figure 4-2: Two Axis Joystick Interface (to the I/O board) www.aerotech.com...

  • Page 104: Handwheel Interface

    IMPORTANT: You can find instructions on how to enable the handwheel in the online Help file. Connect a handwheel to the Aux I/O as shown in Figure 4-3 Figure 4-4. Figure 4-3: Handwheel Interconnection to Aux I/O Connector Figure 4-4: Handwheel Interconnection to the Aux I/O through a BBA32 Module www.aerotech.com...

  • Page 105: Chapter 5: Maintenance

    The light is configured to blink for setup. Table 5-2: Troubleshooting Symptom Possible Cause and Solution Make sure the power LED is illuminated (this indicates that power is present). No Communication Make sure that all communication cables (HyperWire, for example) are fully inserted in their ports. www.aerotech.com...

  • Page 106: Preventative Maintenance

    Internal contamination from the cleaning solution can cause corrosion and electrical short circuits. Do not clean the labels with a cleaning solution because it might remove the label information. www.aerotech.com...

  • Page 107: Fuse Specifications

    Hardware Manual 5.2. Fuse Specifications 5.2. Fuse Specifications WARNING: Replace fuses only with the same type and value. Table 5-4: Control Board Fuse Specifications Aerotech Third Party SCCR Fuse Description Size Littelfuse F100 Control Power at Line Input (L) 2 A S.B.
  • Page 108 5.2. Fuse Specifications iXC4/XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 109: Appendix A: Warranty And Field Service

    All Other Repairs - After Aerotech's evaluation, the buyer shall be notified of the repair cost. At such time the buyer must issue a valid purchase order to cover the cost of the repair and freight, or authorize the product(s) to be shipped back as is, at the buyer's expense.
  • Page 110 Aerotech's approval. On-site Warranty Repair If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts, and cannot be returned to the Aerotech service center for...

  • Page 111: Appendix B: Revision History

    System Wiring (best practices) drawing has been added 2.00 General Update The following sections have been updated: 1.02 Agency Approvals Section 2.3.1. Primary Encoder Inputs The following sections have been updated: 1.01 Section 2.1.2. Section 2.10. 1.00 New Manual www.aerotech.com...
  • Page 112 Appendix B: Revision History iXC4/XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 113: Index

    Brushless Motor Phasing Goal Analog Inputs [-EB1] Brushless Motor Phasing Oscilloscope Example Analog Output 0 on the Aux I/O Connector Brushless Motor Powered Motor Phasing Analog Output 0 Schematic (Aux I/O Connector) Analog Output 0 Specifications (Aux I/O Connector) www.aerotech.com...
  • Page 114 EMC/CE Compliance Digital Input 1 Connector Pinout [-EB1] Enclosure Digital Input 2 Connector [-EB1] Mating Connector Part encoder Numbers absolute 49,69 Digital Input 2 Connector Pinout [-EB1] Encoder and Hall Signal Diagnostics Digital Input Pins on the Aux I/O Connector www.aerotech.com...
  • Page 115 Thermistor Input Schematic Absolute Encoder Schematic (Feedback Connector) Three Phase Stepper Motor Configuration Analog Input 0 Schematic (Aux I/O Connector) TTL Outputs Schematic (PSO) Analog Input Typical Connection [-EB1] Typical STO Configuration Analog Output 0 Schematic (Aux I/O Connector) fluids, dangerous www.aerotech.com...
  • Page 116 IP54 Compliant Three Phase Stepper Motor Connections Isolated Output Current Sinks Schematic (PSO) Motor Supply Connections Isolated Output Current Sources Schematic (PSO) Motor Supply Connector Isolation Mating Connector Part Numbers Wiring Specifications Motor Supply specifications Mounting and Cooling Joystick Interface www.aerotech.com...
  • Page 117 49,69 Feedback Connector serial number Hall-Effect Feedback Pins (Feedback Connector) Sine Wave Encoder (Auxiliary I/O Connector) High-Speed Input Pins (Aux I/O Connector) Sine Wave Encoder Specifications (Feedback Connector) 50 Home Limit Input Pins (Feedback Connector) Motor Power Output Connector www.aerotech.com...

  • Page 118: Table 2-36: Square Wave Encoder Specifications

    Typical STO Configuration Connector Pinout Diagnostics Electrical Specifications Unit Weight External Delay Timer Functional Description User Power Supply specifications Mating Connector Part Numbers Motor Function Relative to the STO Input State Signal Delay Standards Warranty and Field Service Standards Data www.aerotech.com...
  • Page 119 Hardware Manual Index Wire Colors for Aerotech-Supplied Brushless Motor Cables Wire Colors for Aerotech-Supplied DC Brush Motor Cables Wire Colors for Aerotech-Supplied Stepper Motor Cables 44 www.aerotech.com...
  • Page 120 Index iXC4/XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

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